U.S. patent application number 14/173757 was filed with the patent office on 2015-08-06 for cooling of charging cable.
This patent application is currently assigned to Tesla Motors, Inc.. The applicant listed for this patent is Tesla Motors, Inc.. Invention is credited to Joshua W. FERGUSON, Joseph MARDALL, Christopher NEWPORT, Christopher H. VAN DYKE, Yee Shan WOO.
Application Number | 20150217654 14/173757 |
Document ID | / |
Family ID | 53754134 |
Filed Date | 2015-08-06 |
United States Patent
Application |
20150217654 |
Kind Code |
A1 |
WOO; Yee Shan ; et
al. |
August 6, 2015 |
COOLING OF CHARGING CABLE
Abstract
A charging system for an electric vehicle includes: a power
supply; a cable having first and second ends, the first end
attached to the power supply, the cable comprising a charging
conductor and a cooling conduit, each of which extends from the
first end to the second end; and a connector attached to the second
end of the cable, the connector having a form factor corresponding
to a charge port of the electric vehicle; wherein the cooling
conduit is adapted to convey a fluid that cools the charging
conductor.
Inventors: |
WOO; Yee Shan;
(Hillsborough, CA) ; VAN DYKE; Christopher H.;
(San Francisco, CA) ; MARDALL; Joseph; (San
Francisco, CA) ; NEWPORT; Christopher; (San Jose,
CA) ; FERGUSON; Joshua W.; (Alameda, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tesla Motors, Inc. |
Palo Alto |
CA |
US |
|
|
Assignee: |
Tesla Motors, Inc.
Palo Alto
CA
|
Family ID: |
53754134 |
Appl. No.: |
14/173757 |
Filed: |
February 5, 2014 |
Current U.S.
Class: |
320/109 |
Current CPC
Class: |
B60L 53/11 20190201;
B60L 53/16 20190201; Y02T 10/70 20130101; H02J 7/0029 20130101;
Y02T 90/12 20130101; H01R 2103/00 20130101; Y02T 10/7072 20130101;
B60L 53/302 20190201; B60L 53/18 20190201; Y02T 90/14 20130101;
H01B 7/423 20130101; H01R 13/502 20130101; B60L 11/1818
20130101 |
International
Class: |
B60L 11/18 20060101
B60L011/18; H02J 7/00 20060101 H02J007/00; H01B 9/00 20060101
H01B009/00 |
Claims
1. A charging system for an electric vehicle comprising: a power
supply; a cable having first and second ends, the first end
attached to the power supply, the cable comprising a charging
conductor and a cooling conduit, each of which extends from the
first end to the second end; and a connector attached to the second
end of the cable, the connector having a form factor corresponding
to a charge port of the electric vehicle; wherein the cooling
conduit is adapted to convey a fluid that cools the charging
conductor.
2. The charging system of claim 1, wherein the cooling conduit is
adapted so that the fluid is conveyed from the first end to the
second end, and thereafter from the second end to the first
end.
3. The charging system of claim 2, wherein the connector comprises
at least one electric contact held by an armature at the second
end, wherein the cooling conduit forms a loop by the armature so as
to return to the first end.
4. The charging system of claim 3, wherein the loop includes a
connecting piece attached to an inlet portion of the cooling
conduit coming from the first end and to an outlet portion of the
cooling conduit leading toward the first end.
5. The charging system of claim 2, wherein the connector comprises
at least one electric contact held by an armature at the second
end, the armature having an interior cavity with an inlet opening
and an outlet opening, wherein an inlet portion of the cooling
conduit coming from the first end is connected to the inlet
opening, and the outlet opening is connected to an outlet portion
of the cooling conduit leading toward the first end.
6. The charging system of claim 2, having at least first and second
charging conductors, wherein the cooling conduit comprises an inlet
portion coming from the first end and an outlet portion leading
toward the first end, and wherein the charging cable has a cross
section profile in which each of the inlet and outlet portions is
touching each of the first and second charging conductors.
7. The charging system of claim 2, having at least first, second,
third and fourth charging conductors, wherein the cooling conduit
comprises an inlet portion coming from the first end and an outlet
portion leading toward the first end, wherein the charging cable
has a cross section profile in which the inlet portion is touching
at least the first and second charging conductors and in which the
outlet portion is touching at least the third and fourth charging
conductors.
8. The charging system of claim 2, wherein the cooling conduit
forms a fluid channel around at least one electric contact in the
connector.
9. The charging system of claim 2, wherein the cooling conduit
forms a fluid channel around an inside a handle of the
connector.
10. The charging system of claim 1, further comprising a ground
cable that extends from the first to the second end and is touching
the charging conductor and the cooling conduit, wherein the ground
cable is adapted to conduct heat from the charging conductor to the
cooling conduit.
11. The charging system of claim 10, wherein the ground cable has a
braided outer surface that is in thermal contact with the charging
conductor and the cooling conduit.
12. The charging system of claim 10, further comprising at least
one signal cable that extends inside the ground cable from the
first to the second end.
13. The charging system of claim 1, wherein the cooling conduit
conveys a liquid that cools the charging conductor.
14. The charging system of claim 1, wherein the connector includes
a fluid hub that defines an interior fluid path from an inlet
opening to an outlet opening, the interior fluid path traversing
essentially an entire interior of the fluid hub.
15. The charging system of claim 14, wherein the fluid hub
comprises a first part, having the inlet opening, joined to a
second part having the outlet opening, at least one of the first
and second parts having a wall extending into the interior of the
fluid hub, the interior fluid path defined at least in part by the
wall.
16. The charging system of claim 14, wherein the fluid hub further
comprises at least one busbar attached to the fluid hub, the busbar
adapted to be electrically connected to a contact socket of the
connector.
17. The charging system of claim 14, wherein the fluid hub further
comprises at least one circuit component configured for use in
charging the electric vehicle, the circuit component mounted on a
board attached to the fluid hub.
Description
BACKGROUND
[0001] The advancement of electric vehicles has created an
increased need for charging equipment that delivers electric power.
Some such applications (e.g., certain fast-charging vehicle
chargers) are designed to work with continuous currents of 100 Amps
or more. Generally, the higher the current flow in a certain
conductor the more heat is generated. As a result, the conductors
between the charging equipment and the vehicle have traditionally
been sized larger to match the higher current draws.
SUMMARY
[0002] In a first aspect, a charging system for an electric vehicle
includes: a power supply; a cable having first and second ends, the
first end attached to the power supply, the cable comprising a
charging conductor and a cooling conduit, each of which extends
from the first end to the second end; and a connector attached to
the second end of the cable, the connector having a form factor
corresponding to a charge port of the electric vehicle; wherein the
cooling conduit is adapted to convey a fluid that cools the
charging conductor.
[0003] Implementations can include any or all of the following
features. The cooling conduit is adapted so that the fluid is
conveyed from the first end to the second end, and thereafter from
the second end to the first end. The connector comprises at least
one electric contact held by an armature at the second end, wherein
the cooling conduit forms a loop by the armature so as to return to
the first end. The loop includes a connecting piece attached to an
inlet portion of the cooling conduit coming from the first end and
to an outlet portion of the cooling conduit leading toward the
first end. The connector comprises at least one electric contact
held by an armature at the second end, the armature having an
interior cavity with an inlet opening and an outlet opening,
wherein an inlet portion of the cooling conduit coming from the
first end is connected to the inlet opening, and the outlet opening
is connected to an outlet portion of the cooling conduit leading
toward the first end. The charging system has at least first and
second charging conductors, wherein the cooling conduit comprises
an inlet portion coming from the first end and an outlet portion
leading toward the first end, and wherein the charging cable has a
cross section profile in which each of the inlet and outlet
portions is touching each of the first and second charging
conductors. The charging system has at least first, second, third
and fourth charging conductors, wherein the cooling conduit
comprises an inlet portion coming from the first end and an outlet
portion leading toward the first end, wherein the charging cable
has a cross section profile in which the inlet portion is touching
at least the first and second charging conductors and in which the
outlet portion is touching at least the third and fourth charging
conductors. The cooling conduit forms a fluid channel around at
least one electric contact in the connector. The cooling conduit
forms a fluid channel around an inside a handle of the
connector.
[0004] The charging system further includes a ground cable that
extends from the first to the second end and is touching the
charging conductor and the cooling conduit, wherein the ground
cable is adapted to conduct heat from the charging conductor to the
cooling conduit. The ground cable has a braided outer surface that
is in thermal contact with the charging conductor and the cooling
conduit.
[0005] The charging system further includes at least one signal
cable that extends inside the ground cable from the first to the
second end. The cooling conduit conveys a liquid that cools the
charging conductor. The connector includes a fluid hub that defines
an interior fluid path from an inlet opening to an outlet opening,
the interior fluid path traversing essentially an entire interior
of the fluid hub. The fluid hub comprises a first part, having the
inlet opening, joined to a second part having the outlet opening,
at least one of the first and second parts having a wall extending
into the interior of the fluid hub, the interior fluid path defined
at least in part by the wall. The fluid hub further comprises at
least one busbar attached to the fluid hub, the busbar adapted to
be electrically connected to a contact socket of the connector. The
fluid hub further comprises at least one circuit component
configured for use in charging the electric vehicle, the circuit
component mounted on a board attached to the fluid hub.
BRIEF DESCRIPTION OF DRAWINGS
[0006] FIG. 1 shows an example of a charging cable having a cooling
conduit.
[0007] FIG. 2 shows an electric-vehicle system connected to a
charging system.
[0008] FIG. 3 shows an example of a cooling conduit with a U-turn
loop.
[0009] FIG. 4 shows an example of a cooling conduit with a
connecting piece.
[0010] FIG. 5 shows an example of a charging cable connector with
an armature and a cooling conduit.
[0011] FIG. 6 shows an example of an armature having an interior
cavity.
[0012] FIGS. 7-9A show examples of cross section profiles for
charging cables.
[0013] FIGS. 10A-D show other examples of an armature and electric
contacts.
[0014] FIGS. 11-12 show other examples of cross section profiles
for charging cables.
[0015] FIGS. 13A-B show an example of a fluid hub.
[0016] FIG. 14 shows an example of a contact having the fluid hub
of FIGS. 13A-B.
[0017] FIG. 15 shows an example of a component mounted on the
contact of FIG. 14.
[0018] FIG. 16 shows another example of a charging cable having a
cooling conduit.
DETAILED DESCRIPTION
[0019] This document describes examples of systems and techniques
for cooling charging cables. The charging cable that gets connected
to the charge port of an electric vehicle can be cooled by a fluid.
This can provide one or more advantages, such as: more electric
power can be fed through the charging cable; a thinner charging
cable can be used; the charging cable can be made lighter; less
copper can be used in the charging cable; and/or the charging cable
can be made more flexible and therefore easier to handle. While
electric vehicles are mentioned in examples herein, some
implementations can instead or in addition be used in one or more
other contexts, including charging of stationary storage
installations. Also, while charging is described in examples
herein, some implementations can instead or in addition be used
with transfer of electric energy in other contexts, such as when
attaching an electric device to a power supply. Finally, connectors
described in examples herein can be either male or female
connectors.
[0020] FIG. 1 shows an example of a charging cable 100 having a
cooling conduit 102. Generally, the charging cable has a connector
104, a connector housing 106 (part of which is here removed for
visibility) and a cable 108. The connector 104 is designed so as to
be compatible with a charging inlet (e.g., a receptacle) installed
on an electric vehicle, and may therefore be configured according
to one or more standards for electric connectors. The connector
housing 106 is designed to be held by a person, such as when
inserting the connector into a vehicle charge port, and when
removing the connector from the charge port after charging. The
cable 108 forms the connection between the connector 104 and
charging equipment (not shown), and houses not only the cooling
conduit 102 but also at least one charging conductor 110 that is
configured for delivering electric power. In some implementations,
the connector and the connector housing can be manufactured as a
single piece.
[0021] The cooling conduit 102 serves to convey a coolant (e.g., a
liquid) along the length of the charging conductor so as to remove
some or all heat generated by the flow of electric energy. Examples
of coolants or other heat transfer mediums include, but are not
limited to, water, air, oil, phase-changing materials, and other
chemicals. For example, a non-degrading coolant can be chosen that
has sufficient heat capacity. The material for the cooling conduit
can be chosen based on its thermal conductivity and on its
flexibility and durability. Here, the cooling conduit starts at the
beginning of the cable 108 (not shown), and doubles back near the
connector 104. With this and similar implementations, the conduit
can provide cooling along essentially the entire length of the
cable 108 and within the charging connector.
[0022] In some implementations, the coolant reverses flow direction
at or near the connector, for example by way of a U-turn in the
cooling conduit 102. As such, the coolant can be returned to the
system that provides the coolant, such as a reservoir of a cooling
system for the particular charging station to which the charging
cable is attached. As another example, the U-turn can occur outside
of the charging connector, such as in an implementation where
coolant is fed into a vehicle (e.g., during charging) so as to
provide (or enhance) cooling during the charging operation, wherein
the coolant passes back out of the vehicle through the same
charging connector. In other implementations, a one-way flow of
coolant can be provided. For example, the connector that attaches
to the charging inlet of an electric vehicle (or other equipment)
can also have a fluid inlet that is coupled to a coolant reservoir
of the vehicle. As such, the coolant can be used to replenish
coolant in such reservoir.
[0023] FIG. 2 shows an electric-vehicle system 200 connected to a
charging system 202. For example, the system 200 can be part of an
electric vehicle (e.g., a fully electric passenger vehicle) and the
system 202 can be part of charging equipment designed for one or
more types of electric vehicles (e.g., electric-vehicle supply
equipment installed at a private or public location). A charging
cable 204 is schematically illustrated that connects the two
systems. For example, one end of the charging cable is permanently
attached to the system 202 and at the time of charging a user
attaches the other end to a charge port 206 that is part of the
electric vehicle. The charging cable includes one or more electric
conductors 204A (e.g., a copper wire) and a cooling conduit
204B.
[0024] The electric conductor 204A receives electric power from a
power unit 208 within the system 202, which in turn draws
electricity from an external power supply 210, such as from a
generator or an electric grid. In some implementations, the power
unit conditions the supplied power so as to deliver the proper
electric energy to the electric vehicle. For example, incoming AC
or DC can be converted to a suitable form of AC or DC. The electric
conductor can have a ground conductor 212 along some or all of its
length, which can be connected to a ground terminal 214 in the
system 202. During charging, the ground conductor can also be
connected to a corresponding ground terminal 216 in the electric
vehicle, such as to the vehicle chassis.
[0025] In the electric-vehicle system 200, the power conveyed by
the charging cable 204 is provided to at least one onboard charger
218 which feeds electric energy into an energy storage 220 (e.g., a
battery pack of lithium-ion cells). Such stored energy can be used
by one or more electric motor 222 and/or another vehicle component,
such as for propulsion and/or heating of the electric vehicle. In
some implementations, the energy storage can receive electric
energy in at least one other way in addition to the charger 218,
including by regeneration of kinetic energy from a moving
vehicle.
[0026] Returning now to the cooling conduit 204B, it is part of a
cooling system 224 based in the charging system 202. For example,
the cooling system can be contained within the same cabinet or
housing as the supply equipment. In this implementation, a pump 226
receives coolant returning from the charging cable 204 and feeds
the coolant to a cooling unit 228, which can make use of any
cooling technique that is suitable considering the level of heat
involved. For example, a radiator (e.g., one or more heat fins) can
be used, optionally in combination with a fan. From the cooling
unit, the cooled fluid is fed to the inlet of the charging cable,
where it cools the charging conductor and any connector at the end
of the cable. The dimensions of the cooling conduit, and the flow
rate of the coolant, are selected based on the characteristics of
the implementation.
[0027] In other implementations, more than one conduit, pump,
and/or cooling unit, can be used. As another example, the coolant
can flow in the opposite direction in the circuit. In yet another
implementation, the coolant does not circulate but rather is
conveyed from the charging system 202 to the electric-vehicle
system 200. For example, the electric-vehicle system can contain a
reservoir of coolant that is replenished by the supply from the
charging system.
[0028] FIG. 3 shows an example of a cooling conduit with a U-turn
loop. Particularly, the charging cable 100 is here shown with
copper-based terminals 300 (i.e., the ends of the charging
conduits, which can be made of copper, brass or some other copper
alloy, to name a few examples). The cooling conduit 102 loops back
between the copper terminals by way of a U-turn component 302. That
is, the material of the cooling conduit is sufficiently flexible
that it can be bent, without breaking, into the illustrated shape.
For example, this flexibility exists under normal conditions (e.g.,
at room temperature), or it is brought about by treatment of the
conduit (e.g., by heating, forming, molding or fabrication). In
other implementations, the cooling conduit can be routed around a
curved portion of an armature. For example, this can prevent
possible kinks which could restrict coolant flow.
[0029] In some examples described herein, the coolant makes a
U-turn upon reaching the charging connector and thereafter returns
back along the charging cable (e.g., in a circulatory system). In
other implementations, however, the charging cable can serve as a
"pass-through" for fluid (e.g., coolant) into the vehicle or other
equipment being charged. For example, this can be used for
providing coolant/fluid to a vehicle's internal cooling system.
[0030] FIG. 4 shows an example of a cooling conduit with a
connecting piece 400. That is, a cooling tube 402 can consist of an
inlet portion 402A and an outlet portion 402B. The inlet portion
extends from the beginning of the charging cable until its end
where it is coupled to the connecting piece. Similarly, the outlet
portion extends from the connecting piece to the beginning of the
charging cable. The connecting piece can have any suitable form,
including, but not limited to, a knee shape. For example, the
connecting piece can allow the cooling conduit to loop back within
a closer confine (e.g., within a narrower cable housing) than what
would be possible or practical when making a U-turn of the conduit
material itself.
[0031] FIG. 5 shows an example of the charging cable connector 100
with an armature 500 and the cooling conduit 102. Particularly,
part of the connector that was shown in FIG. 1 has here been
removed so that electric contacts 502 are visible. The electric
contacts will mate with corresponding contacts in the charge port
of the electric vehicle so as to provide an electric connection for
the charging. The armature 500 can be manufactured from any
suitable material (e.g., a plastic material) and can have a design
that allows it to hold the electric contacts. The cooling conduit
102 loops back between the copper terminals, similar to the example
above.
[0032] During the charging process, heat is generated not only
along the length of the electric conductors (i.e., within the
copper or other material they are made from) but also within the
connector (i.e., within the electric contact 502 and/or at the
juncture between the conductor and the contact). In some
implementations, significant heat is generated within or near the
connector and a substantial need for cooling in this region can
therefore exist. Such cooling can be provided by the loop of the
cooling conduit which increases the amount of coolant being
circulated near the generated heat.
[0033] In some implementations, another approach can be used to
cool the connector and to provide the coolant into the outlet
portion of the conduit. FIG. 6 shows an example of an armature 600
having an interior cavity 602. The armature 600 can be configured
for use with the charging cable 100 (e.g., FIG. 5) and can provide
the additional benefit of internal cooling. The interior cavity 602
extends through some or all of the interior of the armature and can
have any suitable shape (such as, the shown shape). In some
implementations, the armature is made by a machine fabrication or
molding process, including, but not limited to, injection
molding.
[0034] The armature 600 has at least one inlet 604 providing entry
for the coolant into the interior cavity 602, and at least one
outlet 606 providing exit therefrom. With reference again briefly
to FIG. 4 as an example, the inlet portion 402A can be coupled to
the inlet 604, and the outlet portion 402B can be coupled to the
outlet 606. Accordingly, an at least partially hollow interior of
the armature 600 can provide circulation of coolant therein, which
serves to remove heat generated in the charging.
[0035] In other implementations, a thermal filler material can be
provided between one or more of the contacts 502 (FIG. 5) and the
armature. For example, this can increase thermal transfer and thus
improve the cooling.
[0036] The armature can provide important advantages in the
manufacturing of the charging cable. First, the connections for
electricity (i.e., the conductors) and for coolant (i.e., the
cooling conduit) can be made. Next, the electric contacts (e.g.,
contacts 502 in FIG. 5) can be inserted into the armature so that
they are held by it. Then, the forward ends of the contacts (i.e.,
the ends facing toward the vehicle when used) can be inserted into
a fixture so they are held in the correct position. For example,
such fixture can correspond to the charge port with which the
charging cable should be used. While the contacts are being held,
potting or other material can be applied on or around the contacts
so as to lock them into their correct positions. For example, the
potting material can be thermally conductive. That is, the armature
can serve to orientate the electric contacts into their correct
positions, structurally support the contacts during use (e.g., when
inserting or removing the connector from the vehicle), and provide
cooling at the point where significant heat is generated.
[0037] FIGS. 7-9 show examples of cross section profiles for
charging cables. A profile 700 includes electric conductors 702 and
704, and cooling conduits 706 and 708, inside an outer jacket 710.
The electric conductors can have one or more insulating materials
on the outside to provide electric insulation. Each of the cooling
conduits has one or more channels inside to allow coolant to flow
in at least one direction. Generally, the cooling provided by the
cooling conduits allows the charging cable to be made with a
smaller diameter of the outer jacket than otherwise. Also inside
the cable are ground conductor 712 and one or more additional
members 714, such as signal cables and/or filler material. The
cable components are shown with a certain separation from each
other for clarity, with the understanding that the components could
completely fill the interior of the outer jacket in some
implementations.
[0038] Here, each of the cooling conduits 706 and 708 is touching
each of the electric conductors 702 and 704. Accordingly each of
the cooling conduits is capable of providing cooling to each of the
electric conductors.
[0039] A profile 800 includes electric conductors 802, 804, 806 and
808, and cooling conduits 810 and 812, inside an outer jacket 814.
The ground conductor 712 and the additional member(s) 714 can also
be included within the outer jacket. Each of the cooling conduits
has one or more channels inside. Here, the cooling conduit 810 is
touching each of the electric conductors 802 and 804, and the
cooling conduit 812 is touching each of the electric conductors 806
and 808.
[0040] In a profile 900, the outer jacket 814 contains the electric
conductors 802, 804, 806 and 808, and the cooling conduits 810 and
812. Signal cables (e.g., the additional members 714) are enclosed
within a ground conductor 902. An outer surface 904 of the ground
conductor can be braided, for example as illustrated in the cross
section shown in FIG. 9A. In some implementations, a thin layer of
an insulating material (e.g., plastic) can be provided between the
ground cable and one or more other components. One or more filler
members 906 can be provided inside the outer jacket.
[0041] The ground conductor can be in contact with each of the
electric conductors 802, 804, 806 and 808, and the cooling conduits
810 and 812. Accordingly, the ground conductor can allow heat to be
transferred from the electric conductors to the cooling conduits
and thereby increase the efficiency of the cooling.
[0042] In the examples herein, the dimensions and proportions of
individual cable components, the numbers of components and their
respective positions relative to each other are all for
illustrative purposes only. In other implementations, the
dimensions, proportions, number of components and/or relative
positions can be different. For example, the cross sectional shape
of the conduit could be optimized to maximize surface area contact
with the conductors to increase thermal transfer.
[0043] FIGS. 10A-D show other examples of an armature 1000 and
electric contacts 1002. The armature has a housing 1000A with a
shape that forms a cavity 10008 on the inside and one or more
contact spaces 1000C on the outside. A cap 1004 has a shape that
seals off the cavity, for example by tracing the profile of the
contact space(s). In some implementations, the cap has two fittings
1006 that allow coolant or other fluid to pass into and out of the
interior of the armature. For example, the cooling conduit 102
(FIGS. 1, 3, 4, 5) can be attached to the cap to provide coolant
circulation inside the armature.
[0044] A structure 1008 can provide for attachment of the cap 1004
onto the housing 1000A. For example, one or more bolts or other
fasteners can be used. In some implementations, the joint can be
sealed, such as by a gasket or potting material. FIG. 10B shows the
armature 1000 with the cap 1004 in place.
[0045] FIG. 10C shows the armature 1000 with the electrical
contacts 1002 in place. In some implementations, the
larger-diameter contacts are used to supply electric power, for
example to an energy storage such as a battery pack. For example,
each contact can be provided with a connection surface 1010, such
as a flattened area, configured for use in attaching a conductor,
such as by welding or crimping. One or more smaller-diameter
contacts 1002 can be used for other purposes, including, but not
limited to, as a ground terminal or for communication.
[0046] Referring now specifically to FIG. 10D, it shows the
armature 1000, the electrical contacts 1002 and the connection
surface 1010, here also with one or more fluid channels 1012 that
surround at least part of the electrical contacts. The fluid
channels are coupled to the fittings of the cap, for example via
the hollow interior of the armature, to provide fluid flow. That
is, fluid that is provided to the armature can also, or instead, be
circulated around the electrical contacts by way of the fluid
channels. In some implementations, the fluid channels provide an
essentially spiral-shaped flow pattern that makes a number of laps
(e.g., four) around at least part of the electrical contacts. For
example, this can increase cooling, such as to reduce the
temperature of exterior touch surfaces.
[0047] FIGS. 11-12 show other examples of cross section profiles
1100 and 1200 for charging cables. Beginning with the profile 1100,
it involves the concept of bi-furcating the inward and outward
flows of the fluid (e.g., the coolant). Particularly, the profile
1100 has channels 1102A-B that can be formed by a divider 1104. For
example, the channel 1102A can be used for the inward flow (i.e.,
from the charging equipment toward the connector and the vehicle),
and the channels 1102B can be used for the outward flow (i.e., the
return flow in the opposite direction). That is, upon reaching the
end of the charging cable where the charging connector is attached,
the coolant flow can make a return so that it flows back in the
opposite channels. Such return can be made in form of a U-turn of
the conduit, or by circulating coolant inside an armature, to name
just two examples. In other implementations, the inward and outward
flows can run in the opposite channels.
[0048] Either or both of the channels 1102A-B can have one or more
conductors therein. For example, an electric conductor 1106 can
supply electric energy for the charging, and a conductor 1108 can
provide signaling and/or a ground connection.
[0049] Turning now to the profile 1200, it has a central coolant
conduit 1202 and multiple radially positioned conduits 1204. The
conduits are here formed as integral structures of an extrusion
1206. For example, the extrusion can be formed by extruding a
flexible material (e.g., a polymer) or by a cold-casting
technique.
[0050] The conduits 1202 and 1204 are positioned near or adjacent
multiple conductors 1208 and 1210. For example, the conductor 1208
can supply high-voltage AC or DC for the charging, and the
conductor 1210 can be ground or a signal cable.
[0051] The conduits 1202 and 1204 are coupled to the connector at
the end of the charging cable. In some implementations, the
connector can serve as a turnaround point for coolant that has
flowed in one direction inside the charging cable. For example, the
central conduit 1202 can contain coolant flowing towards the
equipment being charged (e.g., a vehicle), and the radially
positioned conduit(s) 1204 can contain coolant flowing in the
reverse direction. In other implementations, coolant can continue
through the connector without returning, for example into a coolant
reservoir of the vehicle.
[0052] FIGS. 13A-B show an example of a fluid hub 1300. The fluid
hub is here shown in an exploded view where a first part 1302 and a
second part 1304 are visible. Each of the parts can be manufactured
by a molding process, or by a machining process, to name just two
examples. When joined together, such as by a snap-fit assembly,
welding, or application of adhesive, the fluid hub defines a fluid
path 1306 that in this example begins at the first part 1302, where
it enters through an opening 1308, continues through an interior of
the fluid hub, and reaches the second part 1304, where it exits the
fluid hub at an opening 1310. The flow can instead be directed in
the opposite direction through the fluid hub.
[0053] The fluid hub can have one or more interior walls or other
dividers that direct the flow of the liquid. In this example, the
first part 1302 has a wall 1312 that divides the interior volume in
half, and leaves an open passage at the far end for the fluid to
reverse direction. A wall 1314 can be provided in the second part
1304. For example, the walls 1312 and 1314 can form a plane inside
the fluid hub. In some implementations, one of the walls can be
smaller than the other, or omitted entirely. For example, either of
the walls 1312-14 can extend into the opposite part 1302-04 so that
the desired flow path for the fluid is defined.
[0054] The fluid hub 1300 can provide useful thermal exchange with
electric components and/or connectors in a charging system. For
example, the fluid hub can present relatively large surface areas
1316 (on the part 1304) and 1318 (on the part 1302) so that a fluid
inside the hub cools a component on the outside. Some examples will
now be described.
[0055] FIG. 14 shows an example of a contact 1400 having the fluid
hub 1300 of FIGS. 13A-B. The contact has busbars 1402 and 1404
attached on sides of the fluid hub. For example, a thermal epoxy
can be used. In this example, the busbars present relatively large
surfaces that interface with the fluid hub to provide good thermal
exchange.
[0056] The busbars are the electrical connection between the rest
of the charging cable and one or more contact sockets 1406 or
another connector. The contact socket(s) are sized and arranged so
as to match the form factor of a charge port of an electric
vehicle. The socket(s) can be held by an armature 1408 or other
structure.
[0057] The contact socket(s) can be brazed to the busbar(s), which
can allow a larger thermal transfer area. As another example, the
contact socket(s) can be swaged to create an enlarged and/or
flattened area for the same function. For example, this can allow
fewer parts to be used, and/or removal of another boundary for
improved thermal transfer. The conductors of the charging cable can
be attached to the busbars by a suitable technique, such as
ultrasonic or resistance welding.
[0058] FIG. 15 shows an example of a component 1500 mounted on the
contact 1400 of FIG. 14. The component 1500 is involved in the
process of charging the electric vehicle, such as in managing flow
of electricity and/or coolant, or in communication between the
vehicle and the external charging equipment. For example, the
component can include one or more circuits created on a printed
circuit board.
[0059] Positioning the circuitry on the fluid hub can provide
useful cooling of such component(s) as well. Also, the architecture
of the contact illustrated in this example allows the cable
attachment locations--e.g., on the busbars--to be jogged relative
to the axis of one or more sockets. This can allow compact
packaging of the component 1500 inside the connector handle. That
is, the cross-sectional footprint of the socket-end of the assembly
can be made smaller.
[0060] FIG. 16 shows another example of a charging cable having a
cooling conduit. The charging cable 100, connector 104, connector
housing 106, cable 108 and charging conductor 110 are here similar
to those shown in FIG. 1. However, the cooling conduit 102 here
leads into a fluid channel 1600 that wraps around inside the handle
of the charging connector. The fluid channel may or may not be
integrated with the housing of the charging connector. For example,
the cooling conduit can run in an inward-facing groove or other
space provided by the connector housing 106. As such, from the
outside (i.e., to the user) the handle can look similar or
identical to another implementation, for example the one in FIG. 1
where the cooling conduit makes a U-turn, or an implementation
where the coolant does not return along the same charging cable
through which it came. However, the fluid channel can provide one
or more advantages, such as improved cooling of the electric
contacts and other components, and/or improved temperature
management of the external surfaces (e.g., where a user grabs or
otherwise touches the equipment).
[0061] In this example, a portion 1602 corresponds to where the
fluid channel 1600 returns into the charging cable 108 so as to
complete the circuit of fluid flow. In other implementations, the
fluid can flow in the opposite direction.
[0062] A number of implementations have been described as examples.
Nevertheless, other implementations are covered by the following
claims.
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